_STP_566-1974.pdf

HANDBOOK OF FATIGUE TESTING Sponsored by ASTM Committee E-9 on Fatigue ASTM SPECIAL TECHNICAL PUBLICATION 566 S.Roy Swanson,Editor List price$17.25 04-566000-30 AMERICAN SOCIETY FOR TESTING AND MATERIALS 1916 Race Street,Philadelphia,Pa.19103?9 by AMERICAN SOCIETY FOR TESTING AND MATERIALS Library of Congress Catalog Card Number:74-83946 NOTE The Society is not responsible,as a body,for the statements and opinions advanced in this publication.Printed in Baltimore,Md,October 1974 Foreword In 1949 Committee E-9 on Fatigue published ASTM STP 91,Manual of Fatigue Testing.The project leading to STP 91 involved the specific writing of eight members of E-9 and the discussions and criticisms of members of the main committee over a period of three years.STP 91 was a modest effort and succeeded in presenting what was then considered to be the current practice and views of E-9 members.The present Handbook of Fatigue Testing is the culmination of an ex-tensive attempt to survey and document the broad facets of fatigue test-ing.Subject matter was provided by a large number of E-9 members to an editorial group initially headed by Foster B.Stulen and Professor S.M.Marco,both of whom are now deceased.Consolidation of this input has been completed under the editorship of Dr.S.Roy Swanson,with some major changes in emphasis.The reader will find a definite attempt to discuss fatigue machines,test techniques,and associated equipment that can satisfy the requirements of a modern research person or test engineer.More often than not,their needs reflect the desire to test material,com-ponents,and structures under conditions that clearly simulate service loading and environments.As Chairman of Committee E-9,I am grateful for the time and effort that Dr.Swanson put into completing this handbook.I am also grateful to those individuals specifically cited in the Editors brief Preface.W.S.Hyler,Chairman ASTM Committee E-9 on Fatigue Zeitschr.f.Bouwesen 1860 e D W Apporat zurn Probiren der WiderstondsfJhigkeit yon Wagen-Achsen gegen wiederholte Biegungen.!Ii:i W Y W6hlers machine 3br fatigue testing of railway axles.800 600 400 Steel supplied in 1862 sS:rs 200,1 J 1 10 4 tO 5 Cycles 1o Foilure WOhlers S-N curves for Krupp axle steel.I Preface This handbook contains contributions from a large number of ASTM Committee E-9 members.My task has been to take this information and distill it into a unified theme.Because of my background and interests,the unified theme embraces fatigue testing under simulated loading conditions.For this reason,there is considerable emphasis on servocontrolled fatigue test systems and allied equipment.This concentration on modern equipment appears to be particularly important for the young research worker or test engineer,since it is this sort of equipment to which he will be introduced.I should like to recognize with special gratitude those individuals who have spent long hours reviewing and criticizing the various drafts.Spe-cifically,I would like to thank John Bennett,Ron Broderick,Horace Grover,Herbert Hardrath,Walter Hyler,Harold Reemsnyder,and Dick Thurston.These gentlemen formed the review board which has guided my efforts over the past few years.S.Roy Swanson Editor Related ASTM Publications Manual on Low Cycle Fatigue Testing,STP 465(1970),$12.50,04-465000-30 Cyclic Stress-Strain BehaviormAnalysis,Experimentation,and Fatigue Prediction,STP 519(1973),$28.00,04-519000-30 Fatigue at Elevated Temperatures,STP 520(1973),$45.50,04-520000-30 Contents Chapter Chapter Chapter l-Introduction 1 1.1 Purpose 1 1.2 Scope 2 2-Considerations in the Design of the Fatigue Test Program 4 2.1 Introduction 4 2.2 General Planning 5 2.2.1 Objectives S 2.2.2 Constraints 7 2.2.3 Cost Estimation 7 2.3 Test Program Design 8 2.3.1 Requirements of a Sound Experiment 9 2.3.2 Specimen Considerations 10 2.4 Conduct of a Program 12 2.4.1 Test Procedure 12 2.4.2 Test Precautions 13 2.5 Presentation of Data 14 2.5.1 Analysis 14 2.5.2 Reporting 15 2.6 Multilaboratory Test Programs 1S 2.6.1 Multilaboratory Data Generation 15 2.6.2 Interlaboratory Test Programs 16 2.7 Final Remarks 18 3-Basic Elements of a Fatigue Test System 19 3.1 Introduction 19 3.2 The Load Train 19 3.3 Power Supply 23 3.4 Controls 23 3.4.1 Programming 23 3.4.2 Sensors 25 3.4.3 Transducer Conditioners 29 3.5 Readout Devices 30 3.5.1 Oscilloscopes 30 3.5.2 Recorders 31 3.6 Safety Cut-Offs 31 3.7 Devices to Alter the Mode of L9ading 32 Chapter 4 Drive Systems for Conventional Fatigue Testing Machines 37 4.1 Introduction 37 4.2 Features of Test Systems 38 4.2.1 Parameter Under Control 38 4.2.2 Programming Capability 39 4.2.3 Control Mode 43 4.2.4 Closed Loop Control 46 4.2.5 Energy Transfer 50 4.2.5.1 Hydraulic Actuators 51 4.2.6 Energy Conservation 56 4.3 Axial-Load Fatigue-Testing Systems 58 4.3.1 Mechanical Drive Systems 58 4.3.2 Electromagnetic Shakers 60 4.3.3 Pulsators 62 4.4 Bending Machines 63 4.4.1 Rotating Beam Machines 65 4.5 Rolling Contact Fatigue 69 4.5.1 Roll